Apparatus for winding strands on elongated members



July 28, 1964 w, BOHANNON, JR 3,142,450

APPARATUS FOR WINDING STRANDS on ELONGATITZD MEMBERS Filed Dec. 22, 1961 United States Patent 3,142,450 APPARATUS FOR WINDING STRANDS 0N ELONGATED MEMBERS William D. Bohannon, Jr., Burlington, N.C., assignor to Western Electric Company, Incorporated, New York,

N.Y., a corporation of New York Filed Dec. 22, 1961, Ser. No. 161,737 11 Claims. (Cl. 242-9) This invention relates to apparatus for winding strands on elongated members and more particularly to apparatus for winding a series of coils on an indeterminate length of carrier wire.

In the manufacture of certain articles, it is sometimes necessary to wind a strand around the outer surface of an elongated member. More particularly, in the manufacture of articles such as miniature electrical solenoid coils, it is necessary to wind delicate strands of coil wire onto a carrier wire. Research indicates that it is advantageous to serve the coil wire along a fixed line and traverse the carrier wire along a line that is perpendicular to the line of coil wire. Additionally, optimum results are obtained when the carrier wire is traversed under constant tension inasmuch as the carrier wire is not unevenly stretched and may thereby receive closely spaced, uniform turns of coil wire.

An object of this invention is to provide a new and improved apparatus for winding strands on an elongated member.

Another object of this invention resides in the provision of facilities for winding closely spaced, uniform turns of delicate coil wire on a carrier wire.

Still another object of this invention is the provision of facilities for reciprocating a first strand under constant tension through a strand serving mechanism which functions to guide and wind a second strand at right angles onto the first strand.

A further object of this invention resides in the provision of a strand-serving instrumentality having a central bore for receiving a reciprocating carrier wire which is maintained under constant tension in conjunction with facilities formed in the instrumentality for maintaining the carrier wire in a first path and guiding and winding a served strand in a second path that is perpendicular to the first path.

A still further object of this invention is the provision of indexable facilities for clamping the leading end of a carrier wire in successive positions in conjunction with a coaxial strand serving instrumentality for winding a coil at each position to form a series of interconnected coils on the carrier wire.

With these and other objects in view, the present invention contemplates a mechanism for winding a series of spaced coils on an indeterminate length of reciprocating carrier wire. A leading end of the carrier wire is supplied from a reel through the bore of a hollow shaft to a clamp device that is mounted on a traverse arm for indexing successive sections of carrier wire into alignment with a guide slot formed in the hollow shaft. A serving head mounted coaxially on the hollow shaft supplies strand through the slot whereafter it is secured toand maintained under tension by a hook to form a loop of strand that is connected to a first coil that has previously been wound on the carrier wire.

The shaft is rotated to wind a first layer of helical turns of strand on the carrier wire. During the winding a traverse mechanism reciprocates the aligned section of carrier wire relative to the slot against the action of a torque motor connected to the reel for maintaining the carrier wire under constant tension. As the carrier wire reciprocates, a second layer of strand overlaps the first layer to form a second coil connected to the first coil by the loop.

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Other objects and advantages of the present invention will be apparent from the following detailed description when considered in conjunction with the accompanying drawings wherein:

FIG. 1 is a side elevational view of a coil winder having a torque motor driven supply reel and a traverse mechanism for reciprocating a carrier wire relative to a rotating strand serving head which winds a series of coils on the carrier wire according to the principles of the invention;

FIG. 2 is an enlarged perspective view of the serving head shown in FIG. 1 illustrating a guide finger attached thereto and provided with an axial bore for receiving the reciprocating carrier Wire;

FIG. 3 is an enlarged perspective view of the guide finger shown in FIG. 2 illustrating a guide slot formed therein perpendicular to the axial bore for guiding a strand at right angles to the reciprocating carrier wire;

FIG. 4 is an end view of the guide finger illustrated in FIG. 3 showing a cutout formed in the finger for receiving and guiding a coil as it is wound on the carrier wire;

FIG. 5 is a cross-sectional view taken on line 5-5 of FIG. 4 showing a strand advancing through the slot and being wound on the carrier wire as the guide finger rotates;

FIG. 6 is a cross-sectional view taken on lines 66 of FIG. 4 showing a first tapered vertical wall of the cutout intersecting the axial bore of the guide finger;

FIG. 7 is a cross-sectional view taken on line 77 of FIG. 4 showing a second wall of the cutout sloping toward the axial bore for cooperation with the first wall to direct the coiled strand into the axial bore as the carrier wire reciprocates; and

FIG. 8 is a sectional view of a series of miniature solenoid coils which may be wound on the carrier wire by the apparatus shown in the preceding views.

Referring first to FIG. 8, an article 10 which may be manufactured by the apparatus shown in the other views is an elongated member 11, such as a strand, core, carrier wire, etc. having wound thereon overlapping layers 12 of helically coiled strand 13, such as coil wire, thread, etc. Overlapping layers 12 form coils 14 which are wound on the carrier wire at spaced intervals along its length and are interconnected by loops 16 of strand. The coils 14 may be used, for example, as actuator coils in miniature relays or solenoids.

In general, referring to FIGS. 1 and 2, an indeterminate length of carrier wire 11 is supplied from a reel 18 and extends through a hollow shaft 19 having a strand serving head 20 and a guide finger or rod 21 mounted thereon. The carrier wire 11 is secured to a clamp mechanism 23 that is mounted on a traverse mechanism 24. The traverse mechanism 24 reciprocates the carrier wire 11 in the shaft 19 while a torque motor 26 connected to the reel 18 applies a constant tension on the carrier wire. Strand 13 served from the serving head 20 passes through a guide slot 27 formed in the guide finger 21 and is secured to a hook device 28 to form the loop 16 between a first wound coil 30 and a second coil 31.

In the operation of the apparatus, the carrier wire 11 reciprocates relative to the guide slot 27 and the strand 13 is served from the serving head 20 through the guide slot. The guide slot 27 maintains the strand 13 perpendicular to the carrier wire 11 as the guide finger 21 winds the strand to form a coil 14 thereon. The walls of a notch or cut-out 32 formed in the guide finger 21 support the coil 14 as it reciprocates with the carrier wire 11 during the winding operation.

Referring in detail to FIG. 1 of the drawings, the torque motor 26 is shown mounted on a frame 34 and connected to the reel 18. The carrier wire 11 emanates from the reel 18 around an idler pulley 35 and through a bore 36 formed in the hollow shaft 19. A housing 37 supported on the frame 34 is shown cut away to expose a drive motor 38 which is also mounted on the frame. A suitable mechanism, such as a gear train 39, is actuated by the drive motor 38 for rotating the shaft 19.

The carrier wire 11 extends through a bore 41 (see also FIG. 3) formed in the guide finger 21 and is secured to the clamp mechanism 23. The clamp mechanism 23 includes a block 42 that is slidably mounted on a traverse arm or rod 43. A vise-type clamp 44 is provided on the block 42 for holding the leading end of the carrier wire 11. The traverse arm 43 is provided with a series of spaced, locking apertures 46 (see also FIG. 2), the spacing of which corresponds to the desired axial spacing between the coils 14 on the wire 11. A pin 47 may be pushed through an aperture 48 formed in the block 42 into one of the spaced apertures 46 to lock the block in position on the traverse arm 43. By indexing the block 42 on the traverse arm 43, the leading end of the carrier wire 11 is successively advanced away from the guide finger 21 to present successive sections of carrier wire 11 in general alignment with the guide slot 27 for receiving a coil 14.

The traverse mechanism 24 includes a motor 51 that is secured to the frame 34 for rotating a barrel cam 52. A cam follower 53 received in a cam track 54 is moved to and fro upon rotation of the cam 52 for sliding a shaft 56 in pairs of spaced journals 57. Connecting bars 58 secured to the traverse arm 43 and the shaft 56 transmit the reciprocatory movement to the traverse arm for effectuating reciprocation of the carrier wire 11 during the winding operation. As the traverse arm 43 reciprocates the carrier wire 11, the torque motor 26 is effective to maintain the carrier wire under constant tension against the action of the traverse arm 43 so that the carrier wire is evenly stretched for receiving uniform turns of strand 13 from the serving head 20.

The serving head 20 includes a disc 64 fixedly mounted on the drive shaft 19 and a bobbin 61 which is mounted for rotation on the shaft 19 for serving strand 13 against the action of a standard, spring-actuated friction brake 62. The strand 13 is served or payed from the bobbin 61 through a radial slot 63 (FIG. 2) formed in the disc 64. The strand 13 advances from the radial slot 63 into the guide slot 27 formed in the guide finger 21 (FIG. 3). The guide finger 21 may be formed integral with the drive shaft 19 or may be fabricated separately and secured to the shaft by suitable means such as screw threads (not shown). The guide slot 27 is formed in the guide finger 21 perpendicular to the bore 41 for guiding or maintaining the strand 13 served from the head 20 in a path that is perpendicular to the carrier wire 11 (as shown in FIGS. 3 and 7).

Prior to each winding operation, the leading end of the strand 13 that is received in the guide slot 27 is secured to the hook device 28 (FIG. 2) to form the loop 16 that connects the next or second coil 31 to be wound with the first wound coil 30. The hook device 28 includes a second block 66 that is mounted to the traverse arm 43. The second block 66 supports a bracket 67. A hook or anchoring section 68 is formed on the bracket 67 by a pair of adjacent notches 69 for securing the loop 16 during the winding operation. Strand 13 is interlaced through the notches 69 to maintain the loop 16 taut so that the strand in the guide slot 27 is under tension. Thus, there is no slack or loose strand 13 in the area of the guide slot 27 which would form loose turns during the first few revolutions of the guide finger 21 at the start of the next winding operation. Rather, the initial rotation of the finger 21 immediately pulls strand 13 through the guide slot 27 and winds tight turns on the carrier wire 11.

Referring to FIG. 3, the notch 32 is shown formed in the right end of the guide finger 21. As shown in FIG. 4, the respective vertical and horizontal walls 71 and 72 of the notch 32 intersect and form an arcuate surface 73 which is positioned to the left of the finger axis adjacent the point of intersection of the guide slot 27 and the walls. The walls 71 and 72 of the notch 32 respectively slope to the right and downwardly (as viewed in FIG. 4) toward and intersect a restricted section 74 of the bore 41 (see FIGS. 6 and 7).

In the operation of the apparatus, the leading end of the carrier wire 11 is advanced through the bores 36 and 41 and is secured to the vise-type clamp 44 leaving a predetermined space between the first coil 30 and the end of the finger 21. The loop 16 of strand 13 is threaded through the notches 69 and thereby maintained taut to apply tension to the strand in the guide slot 27. The traverse mechanism 24 and the torque motor 26 are then operated and cooperatively maintain under constant tension and reciprocate the carrier wire 11 through the bores 36 and 41. The drive motor 38 rotates the drive shaft 19 which renders the serving head 20 effective to commence the winding operation by serving strand 13 through the slots 27 and 63.

As the winding operation commences, the arcuate section 73 and the walls 71 and 72 of the notch 32 support the carrier wire 11 against transverse movement relative to the axis of the guide finger 21 (FIG. 4). The drive shaft 19 rotates the guide finger 21 whereupon a wall 76 of the slot 27 (FIGS. 3 and 5) is forced against the strand 13 to wind turns of strand on the supported carrier wire 11. As the turns are wound, the carrier wire 11 moves longitudinally relative to the guide slot 27 to receive a series of helical turns which form a layer 12 of turns of strand. The guide slot 27 is efiective to maintain the path of advancement of the strand 13 perpendicular to the carrier wire 11 so that the helical turns are wound tightly against each other.

As shown in FIG. 6, the sloping wall 71 supports this layer 12 of turns as the carrier wire 11 advances out of or away from the bore 41. Upon reversal of the traversing direction, the carrier wire 11 advances into or toward the bore 41 (see FIG. 7) whereupon a second or outer layer 79 of turns is wound on and overlaps the first layer 12. Because the walls 71 and 72 of the notch slope toward the bore 41, the second layer 79 is guided and directed into the bore and prevents the first layer 12 from snagging on a leading edge 81 of the guide finger 21. The winding is continued for a predetermined number of reciprocations until a second coil 31 (FIG. 2) having a desired number of layers is formed on the carrier wire 11. When the second coil 31 is completed, the apparatus is stopped, the loop 16 disconnected from the hook device 28, and the clamp mechanism 23 adjusted and locked on the traverse arm 43 leaving a similar space between the second coil 31 and the finger 21. Another loop is se cured to the hook device 28 whereupon the apparatus is restored to operation to wind the next successive coil on the carrier wire 11.

It is to be understood that the above-described arrangements are simply illustrative of the application of the principles of this invention. Numerous other arrangements may be readily devised by those skilled in the art which will embody the principles of the invention and fall within the spirit and scope thereof.

What is claimed is:

1. In a device for serving strand on a flexible elongated member, means for moving the member in a reciprocatory path along a longitudinal axis, means for applying a constant tension on the moving member, means for supplying strand, guide means for maintaining the strand in a path that is perpendicular to the moving member, and means for rotating the guide means to wind the strand on the moving member while the member is reciprocating.

2. In a device for winding a strand onto a carrier wire, a rotating shaft having a bore for receiving the carrier wire, a head mounted on the shaft for carrying a supply of strand, a traversing mechanism for reciprocating the carrier wire, and means for supplying carrier wire through the bore under constant tension, said shaft having a slot formed therein perpendicular to the bore for guiding the strand from the head onto the reciprocating carrier wire to wind coils of strand on the carrier wire.

3. In a mechanism for winding a coil on a wire, a guide member provided with an axial bore for receiving the Wire, said guide member having a guide slot formed perpendicular to said bore, means for supplying strand to said guide slot, means for rotating the guide member to wind the strand on the wire, means for reciprocating the wire past the guide slot to receive a coil of strand, and means for applying constant tension to the reciprocating wire.

4. In a coil winding apparatus, a wire supply reel, a guide finger provided with a longitudinal axial bore for receiving Wire from the reel, a serving head for supporting a supply of strand, said finger provided with a guide slot formed perpendicular to the axial bore for receiving strand from the serving head, drive means for rotating the head and the finger to Wind turns of strand on the wire, traversing means for reciprocating the wire in the bore to overlap the turns of strand to form a coil, said finger provided with a cutout section for limiting movement of the coil and the wire in a direction that is transverse to the longitudinal axis of the finger, and a torque motor connected to the reel for maintaining the reciprocating carrier wire under constant tension.

5. In a coil winding mechanism, a reel for supplying carrier wire, means for traversing the carrier wire, means connected to the reel for maintaining the carrier wire under constant tension against the action of the traversing means, a hollow rotating shaft mounted coaxially with the traversing carrier wire, said shaft having a slot formed therein perpendicular to the carrier wire, and a serving head mounted on the shaft for supplying a strand through said slot to wind helical layers of strand on the traversing carrier wire, said shaft provided with an angular cutout section having walls extending in the direction of traverse for supporting the layers of strand against the walls while guiding the layers of strand into the hollow shaft.

6. In a device for winding a coil of strand on a carrier Wire, a reel for supplying carrier wire, a serving head for supplying strand, a guide rod provided with a bore for receiving the carrier wire, said guide rod having a slot for guiding the strand from the serving head to the carrier wire along a path that is perpendicular to the carrier wire, said guide rod provided with a cutout section having sloping walls extending from one end thereof toward the bore, means for rotating the serving head and the guide rod to wind a layer of helical turns of strand on the carrier wire, a traverse mechanism for reciprocating the carrier wire to slide the layer of turns along the sloping walls to guide the layer of turns into the bore and overlap the layers to form a coil, and means connected to the reel for maintaining the carrier wire under constant tension,

7. In an apparatus for winding a series of spaced coils on a core wire, a hollow winding head for supporting a supply of coil wire, means for anchoring a section of the coil wire, a reciprocating rod attached to said anchoring means, a reel for supplying core Wire through said winding head, means selectively clamped along said rod for securing the end of said core wire to said rod, means connected to said reel for maintaining the reciprocating core wire under constant tension, and means for rotating said winding head to lay convolutions of coil wire on said reciprocating core wire following each selective clamping of said securing means to said reciprocating rod.

8. In a device for winding a series of coils on a carrier wire, said coils interconnected by a loop of strand, a hollow guide finger mounted coaxially with the carrier wire, a head for supporting a supply of strand, said finger having a slot for guiding the strand from the head to the carrier wire, a hook spaced from the slot for maintaining under tension a loop of strand extending through the slot and connected to a first coil wound on the carrier wire, means for rotating the head and the finger to wind turns of strand on the carrier wire, and means for reciprocating the hook and the carrier wire to overlap the turns of strand to form a second coil connected to the first coil by the tensioned loop, and means for maintaining the carrier wire under constant tension.

9. In a device for Winding a series of spaced coils on a carrier wire, said coils interconnected by a loop of strand, a guide rod having a bore for receiving the carrier wire, said guide rod having a slot formed therein perpendicular to the bore, means for clamping the leading end of the carrier wire, means for selectively locking the clamping means at points spaced from the slot a distance equal to the desired spacing of the coils, means for serving strand to the slot, means for hooking a loop extending through the slot and connected to a first coil, means for rotating the guide rod to wind layers of strand turns on the carrier Wire, means for reciprocating the clamping means to overlap the layers of turns to form a second coil connected by the loop of the first coil, and means for applying a constant tension on the reciprocating carrier wire.

10. In a machine for winding coils of strand on a carrier wire, said coils spaced apart by a predetermined distance and interconnected by a loop of strand, an arm having apertures spaced apart by said predetermined distance, means movable into successive apertures for clamping the leading end of the carrier wire to locate the leading end at successive points spaced apart by multiples of said predetermined length, means for serving strand, said serving means including a finger having a slot formed perpendicular to the carrier wire for guiding strand, means mounted on the arm for hooking one of said loops that extends through the slot to a first wound coil to maintain the loop under tension, means for rotating the strand serving means to wind a layer to strand turns on the carrier wire, means for reciprocating said arm and the carrier wire to overlap the layers to form a second coil connected to the tensioned loop, and means for maintaining the carrier wire under constant tension.

11. In a machine for winding coils on a carrier Wire, said coils spaced apart by a predetermined distance and interconnected by a loop of strand, means for supplying said carrier Wire, an arm having apertures spaced apart by said predetermined distance, means provided with a pin movable into successive apertures for clamping and locating the leading end of the carrier wire at points spaced successively further from the supplying means by multiples of said predetermined distance, a hollow shaft mounted coaxially with the carrier Wire, a head mounted on the shaft for serving strand, said shaft having a slot formed perpendicular to the carrier wire for guiding strand, a hook mounted on the arm for maintaining under tension one of said loops of strand that extends through the slot to a first wound coil, means for rotating the shaft to wind turns of strand on the carrier wire, means for traversing said arm to reciprocate the carrier wire relative to the slot to form a second coil connected to the first coil by the tensioned loops and spaced therefrom by said predetermined distance, and means for applying a constant tension on the carrier wire.

References Cited in the file of this patent UNITED STATES PATENTS 515,597 Lyon Feb. 27, 1894 1,363,422 Lambert Dec. 28, 1920 1,984,405 Fautone et al Dec. 18, 1934 2,342,342 Hotchkiss et a1. Feb. 22, 1944 2,375,861 Martin et al May 15, 1945 3,035,395 Bohannon May 22, 1962 

1. IN A DEVICE FOR SERVING STRAND ON A FLEXIBLE ELONGATED MEMBER, MEANS FOR MOVING THE MEMBER IN A RECIPROCATORY PATH ALONG A LONGITUDINAL AXIS, MEANS FOR APPLYING A CONSTANT TENSION ON THE MOVING MEMBER, MEANS FOR SUPPLYING STRAND, GUIDE MEANS FOR MAINTAINING THE STRAND IN A PATH THAT IS PERPENDICULAR TO THE MOVING MEMBER, AND MEANS FOR ROTATING THE GUIDE MEANS TO WIND THE STRAND ON THE MOVING MEMBER WHILE THE MEMBER IS RECIPROCATING. 